Z-Con Station Installation Guide Rev: 04/15/2011 Rev: 4/15/2011
Table of Contents Z-CON Fueling Station Installation Process .................................................................................2 Pre-Installation Template for Email...............................................................................................4 Z-Con Canopy Kit Installation Guide.............................................................................................5 Required Parts ...........................................................................................
Z-CON Fueling Station Installation Process Pre-Installation Phase 1: 1. Take a total of four photos capturing the following: a. Photo of entire landscape of fueling area (File Name: Store#-City-State-Direct) b. Photo of landscape from a side view (File Name: Store#-City-State-Side) c. Photo of support beam where pump board enclosure will be installed (File Name: Store#-City-State-Enclosure) d. Picture of canopy installation location (File Name: Store#-City-State-Canopy) 2.
2. IR Antenna 2. Email zcon-installation@zonarsystems.com the signed packing slip Installation: 1. Install hardware per the Z‐Con Canopy Kit &Z‐Con Pump Board Installation Guide 2. Provision pump per the Z‐Con Pump Provisioning Application Guide 3. Validate pump per the Z‐Con Pump Validation User Tool Guide 4. Place call to the Pilot Network Team at 865-474-2837; inform the representative Z-Con is currently being installed at the station a.
Pre-Installation Template for Email Date of Installation: Store Number and Location: Number of Lanes Being Installed: Pump/Lane numbers: Installer Name and Phone Number: 1. Attach Photos to email (please see attached file for reference photos) : a. Photo of entire landscape of fueling area (File Name: Store#-City-State-Head on) b. Photo of landscape from a side view (File Name: Store#-City-State-Side View) c.
Z-Con Canopy Kit Installation Guide 5 Rev: 4/15/2011
Contents Required Parts ..............................................................................................................................7 Required Tools & Consumables ...................................................................................................7 Nomenclature................................................................................................................................8 J-Box Installation.....................................................................
Required Parts 1. Canopy Kit (includes the following) a. Z-Con Ultrasonic Sensor Assembly – p/n 80586 b. Z- Con Antenna & IR Receiver Assembly – p/n 80585 c. L-Com 2.4GHz HG2412P Antenna 2. Z-Con Pump Panel Board Assembly – p/n 80476 (Dual) or 80521 (Single) Required Tools & Consumables Tools 1. 2. 3. 4. 5. #2 Phillips Screwdriver 1” NPT Jam Nut tightening tool Calibrated torque wrench Wire cutters Channel locks Consumables 1. Loctite 425 2.
Nomenclature Some items are installed with specific orientations. The Truck Entrance will be the reference point. The Truck Entrance is defined as the side of the station that trucks enter from. See Figure 1.
J-Box Installation 1. Install the J-Box with a minimum of 7 threads protruding out from the Jam Nut. See Figure 2. The nuts must be standard size 1” NPT (~3/16” tall). See Figure 3. WARNING: Using nuts that are taller than 3/16” may damage the plastic housings. NOTE: A seal must be installed between the J-Box and the roof and between the J-Box Cover and the J-Box.
Z-Con Ultrasonic Sensor Assembly Figure 4 - Ultrasonic Sensor Assembly Components 10 Rev: 4/15/2011
1. Install the Ultrasonic Sensor Base to the underside of the canopy where the conduit has been run for that lane and device. See Figure 5. Add washer and nut. Torque the nut to approximately 10 in-lbs. NOTE: See Figure 6 for washer orientation. NOTE: Ensure that the washer is centered on the pipe.
2. Using wire cutters, cut off the Male RJ45 connector from the CAT5 cable attached to the Ultrasonic Sensor (Image A). Also, cut off the Male RJ45 connector from the end of the CAT5 cable that is used to connect to the Ultrasonic Sensor (Image B). (B) (A) 3. Strip back 1”-1.5” of the CAT5 insulation ONLY on both cables. Do NOT strip individual colored wires within CAT5 cables. 4. Use the IDC connectors to splice the CAT5 cable from the Ultrasonic Sensor to the CAT5 cable from the pump board.
Blue Blue Blue/White Blue/White Green Green Brown/White Brown/White Brown Brown 5. Hold the IDC connector with button side down. Insert same colored wires (see above chart) all the way into the IDC connector ports until they reach the top of the IDC connector (Again, Do Not Strip Insulation on Individual Wires). 6. Using channel locks or other tool, crimp button down so that it sits flush in the base of the IDC connector. 7.
8. Install the Ultrasonic Sensor Cover with the cone on the opposite side of the Nut & Washer. See Figure 4 for orientation. NOTE: Ensure that the Receptacle does not get pinched between the rib between the two mount posts in the base and the cover. 9. Apply Loctite 425 to the 2, #8-32 X 3/8 Phillip Pan Head Screws and install as shown in Figure 7. Torque to 4 in-lbs.
Z-Con Antenna & IR Receiver Figure 8 - Antenna & IR Receiver Assembly 1. Install mount plate to the underside of the canopy where the conduit has been run for that specific lane and device. See Figure 9 & 10. Add washer and nut. See Figure 11 for washer orientation.
Figure 9 – Mount Plate Figure 10 – Antenna & IR Receiver Assembly Components Figure 11 - Washer Orientation 2. Install the N-Type Connector from the LMR-200 coax cable on to the HG2412P Antenna and tighten to torque spec of 7 inch/oz.
3. Attach the Antenna & IR Receiver Base (with cover) to the mount plate using four screws as shown below. See Figure 12. Figure 12 – Antenna & IR Receiver Base Screw Locations 4. Remove the Antenna & IR Receiver Cover from the Base by removing four top screws and pulling down on the cover. 5. Using wire cutters, cut off the Male RJ45 connector from the CAT5 cable attached to the IR Receiver (Image A).
7. Use the IDC connectors to splice the CAT5 cable coming from the IR Receiver to the CAT5 cable ran from the pump board location. Match each wire with corresponding colors as follows: CAT5 (From Ultrasonic Sensor) Orange/White Orange Green/White Blue Blue/White Green Brown/White Brown To: CAT5 (From Pump Board) Orange/White Orange Green/White Blue Blue/White Green Brown/White Brown 8. Hold the IDC connector with button side down.
9. Using channel locks or other tool, crimp button down so that it sits flush in the base of the IDC connector. 10. When finished with all wires, tuck exposed IDC connectors into the base of the IR Receiver and secure the Antenna & IR Receiver Cover to the Base using the four top screws. 11. Remove the tape covering the IR Lens. See Figure 13.
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Z-Con Pump Board Installation Guide 21 Rev: 4/15/2011
1. Install Pump Board enclosure to face out bound to traffic a. Enclosure is not be installed towards a lane b.
2.
3. Prior to mounting the Pump Panel Board, route each lane’s cables through their respective grommet holes 4.
5. Once the Pump Panel Board is mounted, connect the appropriate cables to the appropriate connectors (see reference below) a. Power over Ethernet (Top of Board Labeled “A”) b. Ultrasonic Sensor (Bottom Left Labeled “B”) c. Infrared Receiver Interface (Bottom Right Labeled “C”) d. 2.4 GHz RF Coax Connection (Top Left on the Radio Board) – tighten connection to torque spec of 7 inch/oz 6. Verify that all cables have been labeled appropriately (A,B,C) a.
7.
Z-Con Pump Provisioning Application Guide Function: This application is required to apply network settings to the pump board and to calibrate the distance to ground for each lane. It provides a quick and easy way to view and edit the settings of a pump board. Necessary Equipment: 1. 2. 3.
Provisioning Tool Steps: 1. 2. 3. 4. 5. 6. 7. Start at lowest numbered lane Launch the Provisioning Application (from Start Menu or Desktop Icon). Once started, the application attempts to connect to the update server and download a new flatfile. This flatfile will contain the information for every station supported by Z-Con. You will need an internet connection. o The application is installed with the most recent flatfile already provided, so the above step is only necessary on older installations.
19’ 228” 20’ 240” 13. Reset the board by either tapping the AUX pins on the pump board, or clicking the 'Reset the Pump Board' button in the application. Application Functions: Menu Items Options Description File Save Saves the current, enabled values to a .prov file for later use or sharing between laptops. Load Loads a saved .prov file, overwriting any text fields with the values that were saved.
problem persists, the ARM or the EEPROM may be faulty. ‘X’ Could Not Be Opened. Please Double-Check That You’ve Chosen the Right COM Port Occurs when the serial port connection is not made properly. Most common causes are either choosing a serial port from the dropdown currently inactive or choosing a serial port that is currently claimed by another program or device. Check your connections and Device Manager, and shut down any other telnet/terminal programs that may be open on your laptop.
TROUBLESHOOTING RECEIVED ECHO REQUEST LIGHT – solid red – does not light up SENDING ZID LIGHT & BACKGROUND OF ZID INPUT BOX RADIO CONNECTION MADE LIGHT 31 – solid red & solid yellow – does not illuminate COM port is inactive. Verify that the tool is properly plugged into your computer and you’ve chosen the correct COM port in the Pump Validation App. Try toggling the “show active ports” checkbox to refresh the ports drop down box The tool did not receive a radio echo request from the pump board.
Pump Validation Tool User Guide FUNCTION: The Pump Validation Tool ensures that the pumpside hardware has been properly installed and provisioned by testing the connectivity in each lane. NECESSARY EQUIPMENT: 1. Laptop equipped with the Z‐Con Pump Validation Application (supplied on CD) 2. USB cable (provided) 3. Validation Tool (provided) STANDARD USE (Following Installation of the Pump Board) 1. Connect the Pump Validation Tool to your laptop via the USB cable 2.
9. Drive on to the next lane. 10. Reset the application by clicking 'Stop' then 'Start' again.
TROUBLESHOOTING RECEIVED ECHO REQUEST LIGHT – solid red – does not light up SENDING ZID LIGHT & BACKGROUND OF ZID INPUT BOX RADIO CONNECTION MADE LIGHT 34 – solid red & solid yellow – does not illuminate COM port is inactive. Verify that the tool is properly plugged into your computer and you’ve chosen the correct COM port in the Pump Validation App. Try toggling the “show active ports” checkbox to refresh the ports drop down box The tool did not receive a radio echo request from the pump board.
Hardware Troubleshooting Guide The Z-Con Canopy Kit is composed of two devices: an ultrasonic sensor and the Antenna & IR Receiver. These devices are installed on the underside of the canopy in each fuel lane. If validation of the pump hardware is not successful, please refer to the troubleshooting sections below for each device. Ultrasonic Sensor The ultrasonic sensor receives power from the pump board over the CAT5 cable which is also used to transmit data from the ultrasonic sensor to the pump board.
Post Installation Template for Email Response to Zonar Prior to finalizing a sites installation the follow steps must be taken: 1. Date and time call was placed to Zonar Systems Customer Care to verify station 2. Name of representatives from Zonar Systems that verified installation 3. Outstanding issues on site (IE: enclosure issues, power issues etc.) a. Detail outstanding issue and resolution 4. Extra material on site if applicable a.
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